Molding process.



PATENTED APRIls, 19o?.

A. R. MARSTELLER. MOLDING PROCESS.

APPLICATION FILED DB0.10, 190e.

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PATBNTED APR. 1e, 1907.

A. R. MARSTELLER. MOLDING PROCESS. ArPLIoATIoN FILED 1336.10, 19o.

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/vn'wga A. R. MARSTBLLER. MOLDING PROCESS. APPLIUATION FILED 13110.10, 19'06.

PATENTED APR. 16, .1907.

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PATBNTED APR. 16, 1907.

A. R. MARSTBLLER. MULDING PRUGESS. .PPLIGA'JION FILED DEU. 10, 1906.

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No. 850,168. PATENTBD APR. 16, 1907.

A. R. MARSTELLER. MOLDING PROCESS. APPLICATION FILED 1330.10, 1906.

A5 SHEETS-SHEET 5.

AARON R. MARSTELLER, OF ST. LOUIS, MISSOURI.

MOLDING PROCESS.

To ctZZ whom it may concern.-

Be 1t known that I, AARON R. MAEsTELLER,

a citizen of the United States, residiiig at St.

'rices having Louis, and State of Missouri, have invented certain new and useful Improvements in Molding 1"roccsses,.of which the followi ng is a specification.

This invention relates to molding processes, and has particular reference to durable 'mat` the positive contour or impression for the pattern to be reproduced and from which molds of sand or other material may be directly formed.

The invention further contemplates a process of producing said matrices and molds of sand p1' other material therefrom.

The primary object of the present invention is'to effect a saving of time, labor, and expense in metal and other molding, and these objects are attained in this process, first,- by the provision or means whereby two or more sets or gangs. of men can by the employment of durablel matrices work in the formationl of molds from a single pattern and produce such molds from the said matrices with the minimum effort on the part of the operators.

In the practice of my invention it is preferred to construct the durable matrices above referred to of the composition described m ingredients of this composition are litharge, and asphaltum, and when these ingradients are treated in the manner set forth in said patent the resultis a solidified mass which is plastic, elastic, and yet durable, retaining permanently the impression which maybe formed therein in carrying` out my process.

In its broadest aspect the invention resides in the following steps: first, in taking nega tive impressions of the original pattern in sand or in composition, then in taking from the sand or composition thus impressed positive impressions, these Vcast impressions being made in the above-referred-to durable matrices, and finally in constructing the mold for sand, oil,

making the finished article from said mat rices.

The details of construction of my durable matrices, as Well as the nature of my process, Will be apparent from the following description, in which reference is had to the accompanying drawings, forming a part of this specification, like numerals deslgnating-like parts throughout the several views, whereinmy prior patent, No. 785,862. The chief- Specification of Letters Patent. Application led December 10, 1906.

l 'inafter spec-ilically referred to.

Patented Aprn 16,1907. semi No. 347,151.

Figure l is a perspective view of a pattern which may be employed in carrying out my invention. Figs. 2, 3, 4, o, 6, 7, and 8 arc views representing the various ste s in the formation of the sand mold and will) Fig. 9 is a perspective view ol' another l'orni of pattern. l1`igs. 10, 1]., 12, 13, 1.4, 15, and 16 are views illustrating a modified method of carrying be hereout the process which may be employed in connection with the pattern shown in Fig. 9. Fig. 171s a perspective view of a tripod mold ed in accordance -with the adaptation of the process illustrated in Figs. 10 to 16. Figs. 18 19, 20, 21, 22, 23, and 24 are views illustrating the application of my improved process to the formation of molds for very fine work in which the dimensions of the finished product must be perfectly accurate, and Figs. 25 and 26 are plan views of the two faces of the product constructed in accordance with' the adaptation of the process shown in Figs. 18 to 24.

The various iigures above noted will be hereinafter specifically referred to as the descrip tion proceeds, and the steps involved will l be set forth with reference thereto.

In Fig. fish-plate. This pattern is designated by the numeral 1 and has a concave side 2, a convex side 3, and openings 4. In Fig. 2 the numeral designates a box or ask which is lled with mold-sand 6. The pattern l is placed in the ilask 5 in the manner commonly practiced in the art in making the drag half of a mold, as illustrated in Fig. 2. In Fig. 3`A a cope 7 is shown as su erimposed on the iiask 5 and pattern l. a lastic composition 8Which as it hardens takes the negative form of the concave side 2 of the pattern l. After the plastic composition has received its impression in this and in the other instances of its use, as hereinafter recited, it is hardened by heating or 'drying, as fully described in my Patent No. 'Z 85,562 before mentioned. The cope Y, With its composition lling 8, is illustrated in Fig. 5, the negative surface of the pattern being designated by the numeral 9. When the cope is removed from the flask, the sand 6 1 I have illustrated a pattern of a he cope 7 contains IOO los

has the negative impression of the convex side of the pattern ,1. This impressionis clearly shown in Fig 4 and is designated by the numeral 10. The flask 5, having had IIO its-material 6 thus shaped toforin the negative of the convex side of the pattern, is used Aside of the' pattern.

, having a composition filling 12, is employed ioA Whic

ployed in molding-machines in and is superimposed'directly on the flask 5, theifllling 12 being tamped down, so that When it hardens its surface exhibits a positive impression 01 form ofthe convex side 3 of the pattern. This positive surface of the composition 12 is indicated by the numeral 13 in Fig. 6. A cope 14is likewise superim posed upon the cope 7, previously referred to.

he cope 14 has a composition filling .15, which. on account of the negative contour or surface 9 of the filling 8 of the cope 7 assumes a positive impression or contour 16, corresponding to the concave face 2 of the pattern 1. The copes 11 and 14 thus forni durable com osition mold matrices or dies, from the drag 17 and the cope 18 of the final mold are respectively constructed. The cope 18 and drag 17vare illustrated in Fig. 8 and comprise the mold-sand 19 and 20, having the'negativeimpressions of the respective concave and convex sides of the pattern l', suchimpressons being designated 4by the numerals 21 and. 22. The .cope 18 has an olpxenin 23 -formed in the sand filling 19, t oug Which the molten metal is introduced', such metal filling the space 24 between the surfaces 21'and 22 and having the shape and proportions of the original pattern. It will thus be a parent that any number of composition mo d matrices or dies 11 and 14 may be formed from a single pattern in the manner described and that a corresponding number of Workmen may be emprloyed in preparing-the nal molds there- From the positive'mold-matrices 11 and 14 may be formed durable composition molds wherein may be molded terra-cotta or other plastic material. It is also tol be understood that the mold-matrices 11 and 14 may be emplace of patterns o'r pattern-sections.' Fi 9 illustrates a tripod-pattern designate .by the numeral 25. The pattern 25 is used for molding skeleton frames, such as l'ian'gers, Wagon-irons, and fifth-Wheel bear- 5' ings. The pattern 25 as disclosed is pyramida orcone-shaped in form and is supported upon' and `conformable with the sand filling sand 26 of the flask 27. i

.In Fig. 10 is illustrated a step in the process lwhich corresponds to the disclosure of4 Fig. 5. -Instead of a composition cope 8a'.

cope28, having a mold-sand filling 29, may be em loyed. The'use of composition or a ling Will of course depend on the conditions of use.

In the next step the cope 28 serves as a flask, as is shown in Fig. 11, the sand therein having the 'impression 30 in negative of the pattern 25. cope 31, having a composimoved.

tion fillino 32, is superimposed upon the cope '28, the filling 32 being forced into the. iinpression 30, and thus'assume the positive contour 33 of the pattern 25. The next step consists in forming a composition cope 34 from the cope 27, the attern 25 being re- This step prodliices. the cope shown in Fig. 13, which has the projections 35, (forresponding to the recesses in the sand 26 ol' the cope. 27, which are formed by the 'pattern 25. From the composition 'matrix 33 the sand cope 36 (illustrated in Fig. 14) is formed. From the composition pattern 34, which has the impression oi the under side of the pattern 25, the sand drag 37 is formed. The

cope 36 is siperimposed upon the flask 3 7 es is shown in g. 16. The sand of the rope 36 has an opening 39 therein, through which the molten metal is' introduced.

Fig. 17 represents the finished 'product- -l-O of the mold shown in Fig. 16. l

Figs. 18 to 24 illustrate my improved proc ess adapted for use in. making cog-wheels and other objects Where the details must be reproduced With reat exactness. In Fig. 18 l iave illustrate the drag 41 and the cope 42 insuperposed relation, having a filling of sand 43, Which takes the impression of the pattern 44, inserted in the drag 41. .The

pattern 44 represents a bevel-pinion project' which is a central portion 46, concentric therewith and, flush With the surrounding material. 'The' cope 42 having been thus treated is inverted and usedV as a drag in connection With a cope 47', having a composition filling`48. The cope 47 is illustrated in Fig.v

'19, and the. filling 48 after bein tamped into the recess 45 takes the surface orm of an an- IOO IOS

nular elevation or bead 49, conformable in Fig.4 20.) From the co es 47 and 50 the sand mold has its co e an drag formed. This step is illustrate in Figs. 22 and 23, showing the respective uses of the copes 47 and 50, Which are noW employed as drags.. The impression of the rear surface-of the pinion is made in negative from the cope 47.. This is effected by placing Within the space inclosedv by the groove 49 a pattern 54', having the conformation of the rear side of the plnion to :be molded and being accordingly4 provided with ribs 55 and a boss 56. VThe original pattern 44 is placed with its rearwarelly-projectl ing portion in the recess 52- the material of the cope 5()` This ste is shown in Fig. 23, andit is to be noted t at the bevel-teeth 57 on the front face of the pattern are exposed.

From the copes 47 and 50, With the patterns 54 and 44, respectively, therein, we obtain the sand mold illustrated in Fig. 24. The drag 58 of the sand mold is made from the cope 50, and its material has the surface impression 59 in negative of the front face of the pattern 44. The sand-mold cope 6() is formed from the cope 47 in the manner described, and its material has the impression 61 in negative of the projecting parts on the surface of the cope 47 and of the pattern 54 inclosed therein. The cope is superimposed on the drag 58, and its material has anopening therethrough through which the metal to be shaped 1s introduced.

The finished gear-wheel is illustrated in Figs. .25 and 26, in Whichthe front and rear faces, respectively, as formed by the mold shown in Fig. 24 are illustrated.

While I have described my invention specically in connection With three embodiments thereof, .it is to be' understood that said invention is not limited to the exact details mentioned, but may be variouslyT .medi-l ied Within the scope of the appended claim.

Having fully described my invention, I claim- I,

The herein-described process of reducing molds which consists in first em edding apattern in molding-sand leaving one side of the pattern exposed, tamping plastic material adapted to be hardened, upon said exposed side, said sand and plastic material re-' ceiving in negative the impression of the op-` posite sides ofthe pattern, hardenmg said plastic material, then tamping upon the impressed surfaces thus formed plastic-material adapted to be hardened, said last -.name'd plastic material receiving positive impressions of the sides of said pattern, hardening said plastic material to reduce durable rigid matrices and finally 1n producing the drag and cope halves cfa mold from said 

